Air Distribution Apparatus

ABSTRACT

The present embodiments relate to an air distribution apparatus for distributing conditioned airflow from a roof mounted air conditioner to the inside of a vehicle, which includes an inlet port adapted to receive the conditioned airflow from the roof mounted air conditioner. An outlet port, which is disposed adjacent to each longitudinal end of the apparatus, delivers conditioned airflow to the vehicle. An internal supply duct is adapted to evenly split the conditioned airflow to the outlet ports.

CLAIM TO PRIORITY

This continuation patent application claims priority to and benefit of,under 35 U.S.C. § 120, U.S. patent application Ser. No. 17/854,869 filedJun. 30, 2022, and titled “Air Distribution Apparatus”, which claimspriority to U.S. Pat. No. 11,376,925, filed Apr. 15, 2019, which claimspriority to Australian patent application AU 2018901268, filed Apr. 16,2018, also titled “Air Distribution Apparatus”, all of which isincorporated by reference herein.

FIELD OF INVENTION

The present embodiments relate to an air distribution apparatus and, inparticular, to an air distribution apparatus for a vehicle airconditioner.

An air distribution apparatus for a rooftop air conditioner for arecreational vehicle will be described hereinafter with reference tothis application. However, it will be appreciated that the invention isnot limited to this particular field of use.

BACKGROUND

The following discussion of the prior art is intended to place theinvention in an appropriate technical context and enable the associatedadvantages to be fully understood. However, any discussion of the priorart throughout the specification should not be considered as anadmission that such art is widely known or forms part of the commongeneral knowledge in the field.

Air conditioning systems are commonly used in order to make anenvironment more pleasing to occupants. This is particularly relevantwhen the occupants are in a confined space, such as a caravan, mobilehome or other recreational vehicle.

As used herein, the term ‘recreational vehicle’ refers to motor homes,recreational vans, and other similar vehicles. Each of these hasrelatively confined spaces for the occupants to reside in and, as due tothe nature of their use it is often that such vehicles are often usedwith a number of people, such as couples or families.

Conventional recreational vehicles have air conditioning systems thatare built into the vehicle in some manner. For example, the airconditioning unit can be installed into the floor or roof and direct airaround the interior cabin of the vehicles so that conditioned air isthen provided for the occupants.

One problem with roof mounted air conditioners is the operational noisethey generate. This noise is the result of airflow being delivered tothe inside of the vehicle through ceiling mounted air distributionapparatuses, or boxes, containing outlet ports. Additionally, noise cancome from operational noise from the roof mounted air conditioner.

One solution to this problem is to reduce the speed of the fansdelivering the airflow to the vehicle. In this way the velocity andairflow noise across the outlet ports will be reduced. Reducing the fanspeed will also reduce the operational noise of the air conditioner.However, the main problem with this solution is that less airflow isdelivered to the vehicle, which in turn, reduces the distance the airflow can reach. Therefore, by simply reducing the fan speed, the areasof the vehicle that are away from the outlet ports will not have thesame air conditioning affect.

It is an object of the present invention to overcome or ameliorate atleast one of the disadvantages of the prior art, or to provide a usefulalternative.

SUMMARY

According to some embodiments, there is provided an air distributionapparatus for distributing conditioned airflow from a roof mounted airconditioner to the inside of vehicle, the apparatus including:

-   -   an inlet port adapted to receive the conditioned airflow from        the roof mounted air conditioner;    -   at least one outlet port disposed adjacent each longitudinal end        of the apparatus for delivering conditioned airflow to the        vehicle; and    -   an internal supply duct adapted to evenly split the conditioned        airflow to each the outlet port.

In one embodiment, the internal supply duct includes a raised splitterformation and two legs, each leg leading to one longitudinal end.

In one embodiment, each leg includes an upper convex surface forsubstantially redirecting the conditioned airflow.

In one embodiment, each leg includes a lower concave surface forsubstantially redirecting the conditioned airflow.

In one embodiment, each leg includes a lower convex surface downstreamof the lower concave surface such that the height of each leg isrelatively narrower at the centre of each leg.

In one embodiment, the height of each leg is relatively higher at thelateral sides of each leg.

In one embodiment, each leg includes a pair of opposed side walls, theside walls substantially diverging as each leg approaches eachlongitudinal end.

In one embodiment, each side wall is substantially curved.

In one embodiment, the apparatus includes a pair of outlet portsdisposed at each longitudinal end.

In one embodiment, the supply duct includes a divider formationextending along a portion of each leg for evenly separating theconditioned airflow between each outlet port.

In one embodiment, the divider formation extends between the lowerconvex surface and a top surface of each leg.

In one embodiment, the raised splitter formation is substantiallyaligned with the centre axis of the inlet port.

In one embodiment, the air distribution apparatus includes a flexibleinlet supply duct for fluidly connecting the inlet port to the roofmounted vehicle air conditioner.

In one embodiment, each leg includes a cross sectional area whichincreases as each leg respectively approaches each longitudinal end suchthat the velocity of the conditioned airflow reduces thereby reducingthe airflow noise generated at each longitudinal end.

In one embodiment, the flexible inlet supply duct includes largeradiused corners for minimising the flow disturbance of the conditionedairflow into the inlet port.

In one embodiment, each outlet port includes at least one movable louverfor directing the conditioned airflow leaving each outlet port.

In one embodiment, the air distribution apparatus includes a pair oflaterally disposed return air entry ports adapted to return air from thevehicle to the roof mounted vehicle air conditioner.

Reference throughout this specification to “one embodiment”, “someembodiments” or “an embodiment” means that a particular feature,structure or characteristic described in connection with the embodimentis included in at least one embodiment of the present invention. Thus,appearances of the phrases “in one embodiment”, “in some embodiments” or“in an embodiment” in various places throughout this specification arenot necessarily all referring to the same embodiment, but may.Furthermore, the particular features, structures or characteristics maybe combined in any suitable manner, as would be apparent to one ofordinary skill in the art from this disclosure, in one or moreembodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described, by way of exampleonly, with reference to the accompanying drawings in which:

FIG. 1 a is a perspective view of an air conditioner shown installed ona recreational vehicle;

FIG. 1 b is a partly cut away perspective view of an air distributionapparatus according to one embodiment of the present invention showninstalled on the inside of a recreational vehicle of FIG. 1 ;

FIG. 2 is a perspective view of the air conditioner of FIG. 1 a shownwithout its top cover;

FIG. 3 a side cross-sectional view of the air distribution apparatus ofFIG. 1 b;

FIG. 3 b is a further cross-sectional view of the air distributionapparatus of FIG. 1 b removed from the recreational vehicle of FIG. 1 a;

FIG. 4 is an underside perspective view of air distribution apparatus ofFIG. 1 b , installed on the inside of the recreational vehicle of FIG. 1a;

FIG. 5 is a topside perspective view of air distribution apparatus ofFIG. 1 b , removed from the recreational vehicle; and

FIG. 6 top side cross-sectional view of the air distribution apparatusof FIG. 1 b , removed from the recreational vehicle.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Exemplary embodiments of the present invention will now be described indetail with reference to the accompanying drawings. In the drawings, thesame elements are denoted by the same reference numerals throughout. Inthe following description, detailed descriptions of known functions andconfigurations incorporated herein have been omitted for conciseness andclarity.

Referring to the accompanying drawings and initially to FIGS. 1 a and 1b , there is provided an air distribution apparatus 10 for a vehicleroof mounted air conditioner 12. The air distribution apparatus 10 ismounted to the inside ceiling 11 of the vehicle 14. The apparatus 10 isfluidly connected to the air conditioner 12 which is mounted directlyabove on the vehicle's roof surface. Air distribution apparatus 10 isused to distribute the conditioned air from the air conditioner to theinside of the vehicle. In some applications, the air distributionapparatus is known generally as an air distribution box. Further, asused herein, the term vehicle is intended to encompass all suchmotorised and non-motorised vehicles. In the illustrated embodiment, thevehicle is a recreational vehicle such as a caravan or motor home.

Typical to the application, the roof mounted air conditioner 12 is ofthe type known as a packaged air conditioner, whereby the evaporatorcomponents are housed on the same base and within the same housing asthe condenser components. This is contrary to a split type airconditioner, where the condenser components are housed remotely from theevaporator components. For this reason, the air conditioner 12 has anouter cover 16 having openings 20 and 18 to respectively allow for theingress and egress of outside air to the condenser heat exchange area ofthe air conditioner.

More specifically, FIG. 2 shows a view of the air conditioner 12 withthe outer cover 16 removed thereby revealing condenser fan 22 that drawsoutside air into a heat exchange area through openings 20. A compressor24 is provided, which can be of any commercially acceptable typesuitable for a portable air conditioner. Operatively connected to thecompressor is a condenser coil 28.

As is commonly known in the art, air drawn in from the outside is forcedacross the condenser coil 28 to cool the contained refrigerant. Thecooled refrigerant then passes through an expansion valve and into theevaporator coil 30 to absorb heat from the indoor air that passes overit. Therefore, air leaving the evaporator coil becomes conditioned. Theconditioned air is then delivered to the air distribution apparatus 10by way of an evaporator fan 32 which also draws in the return air fromthe inside of the vehicle over the evaporator coil 30. The refrigerantis then compressed and returns to the condenser coil 28 to once again becooled. As should be apparent to those skilled in the art, this processcan be reversed such that the conditioned air is heated rather thancooled.

Referring to FIG. 3 a , we can see a side sectioned view of an exampleembodiment of the air distribution apparatus 10 as it would be installedin FIG. 1 b . As shown, the air distribution apparatus includes a mainbody 33 housing an inlet port 34 adapted to receive conditioned airflow36 from the roof mounted vehicle air conditioner 12. At least one outletport 40 is disposed adjacent each longitudinal end 42 of the apparatus,for delivering conditioned airflow 36 to the vehicle 14.

As best shown in FIG. 4 , the apparatus 10 includes a pair of outletports 40 at each longitudinal end 42. Each outlet port 40 includes apair of vertical spaced pivotally moveable louvers 44 for directing theconditioned airflow leaving each outlet port. In the illustratedembodiment, these louvres are movable during air conditioner operationto evenly distribute the conditioned airflow to different areas of thevehicle. Additionally, louvres 44 may be movable between a completelyopen to a completely closed configuration.

FIG. 5 depicts the apparatus 10 removed from the ceiling of the vehicle14 to illustrate the features on the top surface. As can be seen, theinlet port 34 is connected to a flexible supply duct 38, which is thenconnected to evaporator fan 32 of the roof mounted air conditioner 12when installed (see FIG. 3 a ). By having a flexible supply duct, minorpositional misalignments between the inlet port and the evaporator fan32 during installation can be advantageously compensated for, making theapparatus of the present invention easier and consequently lessexpensive to install. By having an extendible length, the flexiblesupply duct 38 also allows for different roof to ceiling distancesmaking apparatus 10 applicable to different vehicle installations. Theflexible supply duct 38 includes large radiused corners 46 forminimising the flow disturbance and pressure drop of the conditionedairflow into the inlet port 34. Similarly, the inlet port 34 and theevaporator fan 32 have corresponding radiused corners to sealinglyconnect with the flexible supply duct 38 and minimise pressure drop ofthe delivered airflow.

With reference to FIG. 3 b , which shows the apparatus 10 removed frominstallation and partly sectioned, the apparatus 10 further includes aninternal supply duct 48 for evenly distributing the conditioned airflow34 from the inlet port 30 to each longitudinal end 42. The internalsupply duct includes a raised splitter formation 50 substantiallyaligned with the lateral centre axis of the inlet port 34 wheninstalled. The raised splitter formation 50 evenly splits theconditioned airflow 36 between a pair of legs 52, which extend to eachlongitudinal end 42 and the outlet ports 40.

Looking more closely at the inside of the internal supply duct 48, eachleg 52 is defined by an upper convex surface 54 and a lower concavesurface 56, relative to the inside of the internal supply duct. An upperstraight surface 58 and a lower convex surface are respectively provideddownstream of the upper convex and lower concave surfaces. By havingboth the upper convex surface 54, lower concave surface 56 and lowerconvex surface 60, a smooth redirection of the conditioned airflow 36from the air conditioner is established resulting in minimal pressuredrop of the conditioned airflow between the inlet port 34 and eachoutlet port 40.

With reference to FIG. 6 , we can see another sectioned view through theapparatus 10 removed from installation, however, from the perspective ofthe top looking down. Each leg 52 further includes a pair of opposedcurved side walls 62, which generally diverge as each leg transitions toeach longitudinal end 42. Again, the gradual divergence of the sidewalls minimises the pressure drop as the airflow travels across each leg52.

As mentioned earlier, each leg includes a lower convex surface 60, whichtransitions from the lower concave surface 56. As can be seen, the lowerconvex surface extends between the opposed side walls 62 and rises atits centre where it is separated by a divider formation 64. As discussedin more detail below, a divider formation 64 has been provided at eachlongitudinal end 42 to assist in evenly separating the conditionedairflow between each outlet port 40. Whilst not clearly apparent fromthis view, each divider formation 64 extends between upper straightsurface 58 and lower convex surface to completely separate theconditioned airflow between the outlet ports. Divider formation 64 alsoacts to support one end of each pivotally moveable louver 44.

Lower convex surface 60 has a convex profile from the perspective ofeach end of the apparatus. This is contrary to the upper convex surface,which has convex profile when looking at the side of the apparatus 10.Because of the lower convex surface 60, the height of each leg 52 isrelatively narrower at its centre, and relatively higher at the sides ofeach leg. More specifically, lower convex surface 60 provides a reducedcross-sectional area in the centre portion of each leg 52, proximate thedivider formation 64, and an increased cross-sectional area at the sidesof each leg. As should be therefore appreciate it, the airflow will bepromoted to the sides of each leg proximate the sidewalls 62, where alarger cross-sectional area provides less resistance. By separating theairflow in this way, a more even velocity distribution across the outletports is provided with minimal pressure drop loss. This, in turn,minimises the possibility of one outlet port 40 having a greater shareof the airflow than any of the others. Lower convex surface 60terminates with a step 61 leading to each outlet port 40.

Returning to FIG. 4 , return air is supplied to the air conditionerthrough a pair of laterally disposed return air entry ports 66. Thisreturn air travels to the roof top air conditioner via pathways (notshown) on each side of the internal supply duct 48.

The apparatus of the present embodiments is formed primary from mouldedplastics material as is commonly known in the art. However, othermaterials may be used without departing from the scope of the invention.

Referring again to FIGS. 3 a and 3 b , in use, conditioned airflow 36from the roof air conditioner 12 flows into the flexible supply duct 38where it enters the inlet port 32. From there the airflow 36 enters theinternal supply duct 48. The airflow then contacts the raised splitterformation 50 to be evenly split between each leg 52. Conditioned airthen travels to each longitudinally end 42 where it is again split bylower convex surface 60 and the divider formation 64 (FIG. 6 ) to beevenly delivered to each outlet port 40 and into the inside of thevehicle 12. Movable louvers 44 can oscillate during operation to deliverthe conditioned airflow between proximate and distal regions of theinside of the vehicle.

It should be appreciated that due to the configuration of the internalsupply duct 48, an even airflow split is provided between the two legs52. In addition to this, the shape of the side walls 62, the lowerconvex surface 60 and the provision of the divider formation 64, resultin equal flow to each outlet port 40 at each longitudinal end 42. In apractical sense, this means that each outlet port 40 equallyaccommodates the airflow distribution load, resulting in equal exitvelocity leaving the outlet ports and consequently equal noise emissionsfrom each outlet port. This is turn, results in lower overall airdistribution noise level compared to prior art devices where non-evenairflow distribution across the outlet ports create a higher noise fromthe outlet port accommodating the greatest airflow velocity.

Moreover, in a further aspect of the invention, the cross-sectional areaof each of leg 52 increases as it transitions towards each longitudinalend and each lateral side of each leg, due to the diverging sidewalls 62and lower convex surfaces 60 of the internal supply duct 48. In thisway, the velocity of conditioned airflow 36 reduces as it approacheseach longitudinal end 42 but is still evenly split between each outletport 40. This reduction of velocity will, in turn, reduce the noisegenerated by the airflow exiting each outlet port 40.

Additionally, due to the smooth surfaces and gradual redirectionprovided by the configuration of internal supply duct 48 and largeradius corners of the flexible supply duct and inlet port 34, theapparatus of the present invention provides a smooth non-restrictivepath for the conditioned airflow with minimal interruptions for pressureloss. As a result, the speed of the fan providing the conditionedairflow can be slowed to supply a given airflow rate relative to priorart devices. In other words, using the air distribution apparatus of thepresent embodiments, increased airflow will be provided for a givensupply fan rotational speed. Using the apparatus of the presentembodiments compared to prior art devices results in a reduction ofoperational noise from the air conditioner and reduced energy use.

Advantageously, the apparatus of the present embodiments reduces theoverall noise generated inside a recreational vehicle due the operationof a roof top air conditioner. Initially, this is due to providing anequal airflow distribution to each of the outlet ports, minimising thepossibility of a high velocity noisy airflow from any one of the outletports. Secondly, by having an airflow path defined by the internalsupply duct, a minimal pressure loss is provided between the exit of theevaporator fan 32 and each outlet port, resulting in low airflowdistribution noise through the apparatus and relatively lower evaporatorfan rotation speed. And thirdly, by the reducing the velocity of theairflow as it travels towards each outlet port, the noise of the airflowexiting each outlet ports is generally reduced.

It should be appreciated that in the above description of exemplaryembodiments, various features are sometimes grouped together in a singleembodiment, Figure, or description thereof for the purpose ofstreamlining the disclosure and aiding in the understanding of one ormore of the various inventive aspects. This method of disclosure,however, is not to be interpreted as reflecting an intention that theclaimed invention requires more features than are expressly recited ineach claim. Rather, as the following claims reflect, inventive aspectslie in less than all features of a single foregoing disclosedembodiment. Thus, the claims following the Detailed Description arehereby expressly incorporated into this Detailed Description, with eachclaim standing on its own as a separate embodiment of this invention.

In the description provided herein, numerous specific details are setforth. However, it is understood that embodiments of the invention maybe practiced without these specific details. In other instances,well-known methods, structures and techniques have not been shown indetail in order not to obscure an understanding of this description.

Those skilled in the art will recognize that other and furthermodifications may be made thereto without departing from the spirit ofthe invention, and it is intended to claim all such changes andmodifications as falling within the scope of the invention. For example,any formulas given above are merely representative of procedures thatmay be used. Functionality may be added or deleted from the blockdiagrams and operations may be interchanged among functional blocks.Steps may be added or deleted to methods described within the scope ofthe present invention.

FEATURE LIST

-   -   air distribution apparatus 10    -   roof mounted air conditioner 12    -   vehicle 14    -   outer cover 16    -   openings 18 and 20    -   condenser fan 22    -   compressor 24    -   condenser coil 28    -   evaporator coil 30    -   evaporator fan 32    -   main body 33    -   inlet port 34    -   conditioned airflow 36    -   flexible supply duct 38    -   outlet port 40    -   longitudinal end 42    -   moveable louvers 44    -   large radiused corners 46    -   internal supply duct 48    -   raised splitter formation 50    -   upper convex surface 54    -   lower concave surface 56    -   upper straight surface 58    -   lower convex surface 60    -   step 61    -   opposed curved side walls 62    -   divider formation 64    -   return air entry ports 66

1. An air distribution apparatus, comprising: an inlet port, configuredto receive a downward flow of conditioned air from a roof mounted airconditioner; at least two outlet ports configured to distribute theconditioned air from within an interior of a vehicle; a splitterformation located between the inlet port and the at least two outletports, said splitter formation dividing the conditioned air into a firstair flow along a first leg to a first outlet port of said at least twooutlet ports and a second air flow along a second leg to a second ofsaid at least two outlet ports; wherein said first air flow and saidsecond air flow are redirected from said downward flow of conditionedair of said inlet port; wherein said first leg and said second leg eachcomprise a upper convex surface and a lower concave surface which turnsaid first and second air flows; said legs having side walls; a lowerconvex surface extending from said lower concave surface toward said atleast two outlet ports of said legs; and one or more louvers located atends of said legs each comprising.
 2. The air distribution apparatus ofclaim 1, said lower convex surface further comprising curvature betweensaid side walls and a center of said legs.
 3. The air distributionapparatus of claim 1, said first leg and said second leg each having avarying cross-section moving toward respective said ends.
 4. The airdistribution apparatus of claim 1, a distance between said side wallschanging along each said first and second leg.
 5. The air distributionapparatus of claim 1, said legs reducing pressure drop through saidredirection between said inlet port and said ends of said legs.
 6. Theair distribution apparatus of claim 1 wherein said ends of said legsdefine outlet ports.
 7. An air distribution apparatus, comprising: aninlet port configured to be positioned adjacent to a roof line of avehicle having a roof mounted air conditioner disposed above the inletport; a first leg and a second leg defined by a fixed splitter formationdisposed at said inlet port, said first leg extending in a firstdirection and said second leg extending in a second direction oppositesaid first direction; each of said first leg and said second leg formedby an upper convex surface, a lower concave surface, a lower convexsurface, and side walls; each of said first leg and said second leghaving a reduced cross-section at the lower convex surface and increasedcross-section at the side walls to reduce pressure drop while changingdirection of a conditioned air flow between said inlet port and a firstend and a second end of respective said first leg and said second leg;and a first louver located at said first end of said first leg and asecond louver disposed at said second end of said second leg.
 8. The airdistribution apparatus of claim 7, each of said first leg and saidsecond leg having varying cross-section.
 9. The air distributionapparatus of claim 8, each said leg changing width with along adirection of air flow.
 10. The air distribution apparatus of claim 8,said side walls diverging along a length of each said first and secondleg.
 11. The air distribution apparatus of claim 7, said conditioned airflow moving air flow downwardly through said inlet port and turningtoward said first end and said second end.
 12. The air distributionapparatus of claim 7 wherein said first end and said second end eachdefine an outlet port.
 13. The air distribution apparatus of claim 1,said conditioned air being divided by said fixed splitter formation. 14.An air distribution apparatus, comprising: an inlet port, disposed neara roof line of a vehicle and configured to receive a downward flow ofconditioned air from a roof mounted air conditioner; at least two outletports configured to distribute the conditioned air from within aninterior of said vehicle; a splitter formation located between the inletport and the at least two outlet ports, said splitter formation dividingthe conditioned air into a first air flow along a first leg to a firstoutlet port of said at least two outlet ports and a second air flowalong a second leg to a second of said at least two outlet ports;wherein said first air flow and said second air flow change directionfrom said downward flow of said inlet port; each of said first leg andsaid second leg formed by an upper convex surface, a lower concavesurface, a lower convex surface, and side walls; said lower convexsurface extending from said lower concave surface toward said at leasttwo outlet ports of said legs; and said legs each comprising one or morelouvers at said at least two outlet ports.